Komatsu HYDRAULIC EXCAVATOR PC290LC-10 Shop Manual SEN05644-12 PDF

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Komatsu HYDRAULIC EXCAVATOR PC290LC-10 Shop Manual SEN05644-12 – PDF DOWNLOAD

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Komatsu HYDRAULIC EXCAVATOR PC290LC-10 Shop Manual SEN05644-12 – PDF DOWNLOAD

Language : English
Pages :1684
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu HYDRAULIC EXCAVATOR PC290LC-10 Shop Manual SEN05644-12 – PDF DOWNLOAD

SERIAL NUMBERS 15001 and up

General precautions

Inappropriate handling causes an extreme danger. Read and understand what is described in the operation and maintenance manual before operating the machine. Read and understand what is described in this manual before starting the work.

• Before performing any greasing or repairs, read all the safety labels stuck to the machine. For the locations of the safety labels and detailed explanation of precautions, see the operation and maintenance manual.
• Locate a place in the repair workshop to keep the tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.
• When performing any work, always wear the safety shoes and helmet. Do not wear loose work cloths, or clothes with buttons missing. 1. Always wear the protective eyeglasses when hitting parts with a hammer. 2. Always wear the protective eyeglasses when grinding parts with a grinder, etc.
• When performing any work with 2 or more workers, always agree on the working procedure before starting. While working, always keep conversations of the work between your fellow workers and your self on any step of the work. During the work, hang the warning tag of “UNDER WORKING” in the operator’s compartment.
• Only qualified workers must perform the work and operation which require license or qualification.
• Keep the tools in good condition. And learn the correct way to use the tools, and use the proper ones among them. Before starting the work, thoroughly check the tools, lift truck, service vehicle, etc.
• If welding repairs is required, always have a trained and experienced welder with good knowledge of welding perform the work. When performing welding work, always wear welding gloves, apron, shielding goggles, cap, etc.
• Before starting work, warm up your body thoroughly to start work under good condition.
• Avoid continuing work for long hours and take rests with proper intervals to keep your body in good condition. Take a rest in a specified safe place.

TABLE OF CONTENTS:

Komatsu HYDRAULIC EXCAVATOR PC290LC-10 Shop Manual SEN05644-12 – PDF DOWNLOAD

SERIAL NUMBERS 15001 and up

qCover 3
00 Index and foreword 3
Index 4
Foreword, safety and general information 16
Important safety notice 16
How to read the shop manual 23
Explanation of terms for maintenance standard 25
Handling equipment of fuel system devices 27
Handling of intake system parts 28
Handling of hydraulic equipment 29
Method of disconnecting and connecting of push-pull type coupler 31
Handling of electrical equipment 34
How to read electric wire code 42
Precautions when performing operation 45
Practical use of KOMTRAX 50
Standard tightening torque table 51
List of abbreviation 57
Conversion table 62
01 Specification 67
Table of contents 68
Specifications 69
Specification drawings 69
Working range drawings 70
Specifications 71
Weight table 74
Table of fuel, coolant and lubricants 75
10 Structure and function 77
Table of contents 78
Engine and cooling system 79
Engine related parts 79
KVGT 81
EGR system piping drawing 88
EGR system circuit diagram 90
EGR valve 92
EGR cooler 94
KCCV layout drawing 96
KCCV ventilator 98
KDPF 100
Cooling system 104
Power train 106
Power train system 106
Swing circle 108
Swing machinery 109
Final drive 111
Undercarriage and frame 113
Track frame and idler cushion 113
Hydraulic system 115
Hydraulic equipment layout drawing 115
Valve control 117
Hydraulic tank 119
CLSS 121
Main pump 126
Control valve 150
Swing motor 204
Travel motor 215
PPC valve 229
Solenoid valve 250
Attachment circuit selector valve (for high pressure circuit) 253
Attachment circuit selector valve (for low pressure circuit) 255
Center swivel joint 258
Accumulator 260
Work equipment 261
Work equipment 261
Work equipment shim 262
Bucket play adjustment shim 263
Cab and its attachments 264
Cab mount and cab tipping stopper 264
ROPS cab 265
Electrical system 266
Electrical control system 266
Machine monitor system 310
KOMTRAX system 330
Sensor 332
20 Standard value tables 351
Table of contents 352
Standard service value table 353
Standard value table for engine related parts 353
Standard value table for chassis related parts 355
30 Testing and adjusting 369
Table of contents 370
Related information on testing and adjusting 371
Tools for testing and adjusting 371
Sketch of tools for testing and adjusting 375
Engine and cooling system 377
Testing engine speed 377
Testing boost pressure 378
Testing exhaust gas color 379
Testing mass air flow and temperature sensor 382
Testing and adjusting valve clearance 385
Testing compression pressure 388
Measuring blowby pressure 392
Measuring engine oil pressure 393
Measuring EGR valve and KVGT oil pressure 394
Measuring fuel pressure 395
Measuring fuel delivery, return and leakage 401
Bleeding air from fuel system 406
Testing fuel circuit for leakage 408
Handling cylinder cutout mode operation 409
Handling no-injection cranking operation 410
Testing and adjusting air conditioner compressor belt tension 411
Replacing fan belt 412
Power train 413
Testing swing circle bearing clearance 413
Undercarriage and frame 414
Testing and adjusting track tension 414
Hydraulic system 415
Releasing remaining pressure from hydraulic circuit 415
Measuring and adjusting oil pressure in work equipment, swing, and travel circuits 416
Testing oil pressure in control circuit 420
Testing and adjusting oil pressure in pump PC control circuit 421
Testing and adjusting oil pressure in pump LS control circuit 424
Testing output pressure of solenoid valve 429
Measuring PPC valve output pressure 433
Adjusting play of work equipment and swing PPC valves 435
Testing pump swash plate sensor 436
Isolating the parts causing hydraulic drift in work equipment 437
Testing oil leakage 439
Bleeding air from hydraulic circuit 442
Testing and charging accumulator (manufactured by NOK) nitrogen gas pressure for attachment (low pressure side) 444
Testing and charging accumulator nitrogen gas pressure for attachment (high pressure side) 446
Replacing accumulator bladder on high pressure side for accumulator piping 448
Cab and its attachments 454
Testing cab tipping stopper 454
Adjusting mirrors 455
Electrical system 457
Special functions of machine monitor 457
Adjusting rearview camera angle 523
Handling voltage circuit of engine controller 525
Handling battery disconnect switch 526
Testing diodes 527
Pm clinic 528
Pm clinic service 528
40 Troubleshooting 539
Table of contents 540
Related information on troubleshooting 547
Troubleshooting points 547
Sequence of events in troubleshooting 549
Testing before troubleshooting 551
Inspection procedure before troubleshooting 553
Preparation work for troubleshooting of electrical system 581
Classification and procedure for troubleshooting 585
Symptom of probable failure and troubleshooting No 588
Information in troubleshooting table 591
Diagnostic procedure for wiring harness open curcuit of pressure sensor system 593
Connector list and layout 595
Connector contact identification 606
T-branch box and T-branch adapter table 645
Fuse list and location 650
Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement 652
Failure codes table 655
Troubleshooting by failure code (Display of code) 664
Failure code [879AKA] A/C Inner Sensor Open Circuit 664
Failure code [879AKB] A/C Inner Sensor Short Circuit 665
Failure code [879BKA] A/C Outer Sensor Open Circuit 666
Failure code [879BKB] A/C Outer Sensor Short Circuit 667
Failure code [879CKA] Ventilating Sensor Open Circuit 668
Failure code [879CKB] Ventilating Sensor Short Circuit 669
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit 670
Failure code [879EMC] Ventilation Damper Abnormality 671
Failure code [879FMC] Air Mix Damper Abnormality 672
Failure code [879GKX] Refrigerant Abnormality 673
Failure code [989L00] Engine Controller Lock Caution1 674
Failure code [989M00] Engine Controller Lock Caution2 675
Failure code [989N00] Engine Controller Lock Caution3 676
Failure code [A1U0N3] HC desorb request1 677
Failure code [A1U0N4] HC desorb request2 679
Failure code [AA10NX] Air Cleaner Clogging 681
Failure code [AB00KE] Charge Voltage Low 683
Failure code [B@BAZG] Engine Oil Pressure Low 685
Failure code [B@BAZK] Eng Oil Level Low 686
Failure code [B@BCNS] Engine Coolant Overheat 687
Failure code [B@BCZK] Radiator Coolant Level Low 688
Failure code [B@HANS] Hyd Oil Overheat 690
Failure code [CA115] Eng Ne and Bkup Speed Sens Error 691
Failure code [CA122] Chg Air Press Sensor High Error 692
Failure code [CA123] Chg Air Press Sensor Low Error 694
Failure code [CA131] Throttle Sensor High Error 696
Failure code [CA132] Throttle Sensor Low Error 698
Failure code [CA144] Coolant Temp Sens High Error 700
Failure code [CA145] Coolant Temp Sens Low Error 702
Failure code [CA153] Chg Air Temp Sensor High Error 704
Failure code [CA154] Chg Air Temp Sensor Low Error 706
Failure code [CA187] Sensor 2 Supply Volt Low Error 708
Failure code [CA221] Ambient Press Sensor High Error 710
Failure code [CA222] Ambient Press Sensor Low Error 712
Failure code [CA227] Sensor 2 Supply Volt High Error 714
Failure code [CA234] Eng Overspeed 715
Failure code [CA238] Ne Speed Sensor Supply Volt Error 716
Failure code [CA239] Ne Speed Sens Supply Volt High Error 717
Failure code [CA271] IMV/PCV1 Short Error 718
Failure code [CA272] IMV/PCV1 Open Error 720
Failure code [CA295] Ambient Press Sens In Range Error 721
Failure code [CA322] Inj #1(L#1) Open/Short Error 722
Failure code [CA323] Inj #5(L#5) Open/Short Error 724
Failure code [CA324] Inj #3(L#3) Open/Short Error 726
Failure code [CA325] Inj #6(L#6) Open/Short Error 728
Failure code [CA331] Inj #2(L#2) Open/Short Error 730
Failure code [CA332] Inj #4(L#4) Open/Short Error 732
Failure code [CA343] ECM Critical Internal Failure 734
Failure code [CA351] Injectors Drive Circuit Error 735
Failure code [CA352] Sensor 1 Supply Volt Low Error 736
Failure code [CA356] Mass Air Flow Sensor High Error 738
Failure code [CA357] Mass Air Flow Sensor Low Error 740
Failure code [CA386] Sensor 1 Supply Volt High Error 742
Failure code [CA428] Water in Fuel Sensor High Error 743
Failure code [CA429] Water in Fuel Sensor Low Error 745
Failure code [CA435] Eng Oil Press Sw Error 747
Failure code [CA441] Battery Voltage Low Error 748
Failure code [CA442] Battery Voltage High Error 750
Failure code [CA449] Rail Press Very High Error 751
Failure code [CA451] Rail Press Sensor High Error 752
Failure code [CA452] Rail Press Sensor Low Error 754
Failure code [CA488] Chg Air Temp High Torque Derate 755
Failure code [CA515] Rail Press Sens Sup Volt High Error 756
Failure code [CA516] Rail Press Sens Sup Volt Low Error 758
Failure code [CA553] Rail Press High Error 760
Failure code [CA555] Crankcase Press High Error 1 761
Failure code [CA556] Crankcase Press High Error 2 762
Failure code [CA559] Rail Press Low Error 763
Failure code [CA595] Turbo Speed High Error 2 765
Failure code [CA687] Turbo Speed Low Error 766
Failure code [CA689] Eng Ne Speed Sensor Error 768
Failure code [CA691] Intake Air Temp Sens High Error 770
Failure code [CA692] Intake Air Temp Sens Low Error 772
Failure code [CA697] ECM Int Temp Sensor High Error 774
Failure code [CA698] ECM Int Temp Sensor Low Error 775
Failure code [CA731] Eng Bkup Speed Sens Phase Error 776
Failure code [CA778] Eng Bkup Speed Sensor Error 777
Failure code [CA1117] Persistent Data Lost Error 781
Failure code [CA1664] KDOC Malfunction 782
Failure code [CA1691] Regeneration Ineffective 784
Failure code [CA1695] Sensor 5 Supply Volt High Error 786
Failure code [CA1696] Sensor 5 Supply Volt Low Error 788
Failure code [CA1843] Crankcase Press Sens High Error 790
Failure code [CA1844] Crankcase Press Sens Low Error 792
Failure code [CA1879] KDPF Delta P Sensor High Error 794
Failure code [CA1881] KDPF Delta P Sensor Low Error 796
Failure code [CA1883] KDPF Delta P Sens In Range Error 798
Failure code [CA1921] KDPF Soot Load High Error 1 801
Failure code [CA1922] KDPF Soot Load High Error 2 803
Failure code [CA1942] Crankcase Press Sens In Range Error 808
Failure code [CA1993] KDPF Delta Pressure Low Error 809
Failure code [CA2185] Throt Sensor Sup Volt High Error 810
Failure code [CA2186] Throt Sensor Sup Volt Low Error 811
Failure code [CA2249] Rail Press Very Low Error 812
Failure code [CA2271] EGR Valve Pos Sens High Error 813
Failure code [CA2272] EGR Valve Pos Sens Low Error 815
Failure code [CA2288] Turbo Speed High Error 1 818
Failure code [CA2311] IMV Solenoid Error 819
Failure code [CA2349] EGR Valve Solenoid Open Error 820
Failure code [CA2353] EGR Valve Solenoid Short Error 822
Failure code [CA2357] EGR Valve Servo Error 824
Failure code [CA2373] Exh Manifold Press Sens Volt 825
Failure code [CA2374] Exhaust Manifold Press Sens Low Error 827
Failure code [CA2375] EGR Orifice Temp Sens High Error 829
Failure code [CA2376] EGR Orifice Temp Sens Low Error 831
Failure code [CA2381] KVGT Pos Sens High Error 833
Failure code [CA2382] KVGT Pos Sens Low Error 835
Failure code [CA2383] KVGT Solenoid Open Error 837
Failure code [CA2386] KVGT Solenoid Short Error 839
Failure code [CA2387] VGT Servo Error 841
Failure code [CA2554] Exh Manifold Press Sens In Range Error 844
Failure code [CA2555] Grid Htr Relay Volt Low Error 845
Failure code [CA2556] Grid Htr Relay Volt High Error 848
Failure code [CA2637] KDOC Face Plugging 850
Failure code [CA2639] Manual Stationary Regeneration Request 852
Failure code [CA2961] EGR Orifice Temp High Error 1 854
Failure code [CA2973] Chg Air Press Sensor In Range Error 855
Failure code [CA3133] KDPF Outlet Press Sens High Error 856
Failure code [CA3134] KDPF Outlet Press Sens Low Error 858
Failure code [CA3135] KDPF Outlet Press Sens In Range Error 860
Failure code [CA3251] KDOC Inlet Temp High Error 863
Failure code [CA3253] KDOC Temp Error – Non Regeneration 866
Failure code [CA3254] KDOC Outlet Temp High Error 1 868
Failure code [CA3255] KDPF Temp Error – Non Regeneration 871
Failure code [CA3256] KDPF Outlet Temp High Error 1 872
Failure code [CA3311] KDOC Outlet Temp High Error 2 873
Failure code [CA3312] KDPF Outlet Temp High Error 2 874
Failure code [CA3313] KDOC Inlet Temp Sensor Low Error 876
Failure code [CA3314] KDOC Inlet Temp Sens High Error 879
Failure code [CA3315] KDOC Inlet Temp Sens In Range Error 883
Failure code [CA3316] KDOC Outlet Temp Sens Low Error 887
Failure code [CA3317] KDOC Outlet Temp Sens High Error 890
Failure code [CA3318] KDOC Inlet Temp Sens In Range Error 894
Failure code [CA3319] KDPF Outlet Temp Sens High Error 898
Failure code [CA3321] KDPF Outlet Temp Sens Low Error 902
Failure code [CA3322] KDPF Outlet Temp Sens In Range Error 905
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error 909
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error 910
Failure code [CA3741] Rail Press Valve Trip Error 912
Failure code [D110KB] Battery Relay Output Voltage 913
Failure code [D19JKZ] Personal Code Relay Abnormality 915
Failure code [D811MC] KOMTRAX Error 918
Failure code [D862KA] GPS Antenna Open Circuit 919
Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) 920
Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) 922
Failure code [D8AQKR] CAN2 Discon (KOMTRAX) 923
Failure code [DA20MC] Pump Controller 924
Failure code [DA22KK] Pump Solenoid Power Low Error 925
Failure code [DA25KP] 5V Sensor 1 Power Abnormality 927
Failure code [DA29KQ] Model Selection Abnormality 930
Failure code [DA2LKA] Operating Lamp Open Circuit (Pump Con) 932
Failure code [DA2LKB] Operating Lamp Short Circuit (Pump Con) 934
Failure code [DA2QKR] CAN2 Discon (Pump Con) 935
Failure code [DA2RKR] CAN1 Discon (Pump Con) 937
Failure code [DAF0MB] Monitor ROM Abnormality 938
Failure code [DAF0MC] Monitor Error 939
Failure code [DAF8KB] Camera Power Supply Short Circuit 940
Failure code [DAF9KQ] Model Selection Abnormality 942
Failure code [DAFGMC] GPS Module Error 943
Failure code [DAFLKA] Operating Lamp Open Circuit (Monitor) 944
Failure code [DAFLKB] Operating Lamp Short Circuit (Monitor) 946
Failure code [DAFQKR] CAN2 Discon (Monitor) 947
Failure code [DAZ9KQ] A/C Model Selection Abnormality 948
Failure code [DAZQKR] CAN2 Discon (Aircon ECU) 949
Failure code [DB2QKR] CAN2 Discon (Engine Con) 953
Failure code [DB2RKR] CAN1 Discon (Engine Con) 958
Failure code [DGH2KB] Hyd Oil Sensor Short Circuit 962
Failure code [DHA4KA] Air Cleaner Clog Sensor Open Circuit 964
Failure code [DHPAMA] F Pump Press Sensor Abnormality 965
Failure code [DHPBMA] R Pump Press Sensor Abnormality 968
Failure code [DHS3MA] Arm Curl PPC Press Sensor Abnormality 971
Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality 973
Failure code [DHS8MA] Boom Raise PPC Press Sensor Abnormality 976
Failure code [DHS9MA] Boom Lower PPC Press Sensor Abnormality 979
Failure code [DHSAMA] Swing RH PPC Press Sensor Abnormality 982
Failure code [DHSBMA] Swing LH PPC Press Sensor Abnormality 985
Failure code [DHSCMA] Arm Dump PPC Press Sensor Abnormality 988
Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality 991
Failure code [DHSFMA] Travel Fwd LH PPC Press Sensor Abnormality 994
Failure code [DHSGMA] Travel Fwd RH PPC Press Sensor Abnormality 997
Failure code [DHSHMA] Travel Rev LH PPC Press Sensor Abnormality 1000
Failure code [DHSJMA] Travel Rev RH PPC Press Sensor Abnormality 1003
Failure code [DKR0MA] F Pump Swash Plate Sensor Abnormality 1006
Failure code [DKR1MA] R Pump Swash Plate Sensor Abnormality 1009
Failure code [DR21KX] Camera 2 Picture Rev Drive Abnormality 1012
Failure code [DR31KX] Camera 3 Picture Rev Drive Abnormality 1014
Failure code [DV20KB] Travel Alarm Short Circuit 1016
Failure code [DW43KA] Travel Speed Sol Open Circuit 1018
Failure code [DW43KB] Travel Speed Sol Short Circuit 1020
Failure code [DW45KA] Swing Brake Sol Open Circuit 1022
Failure code [DW45KB] Swing Brake Sol Short Circuit 1025
Failure code [DW91KA] Travel Junction Sol Open Circuit 1028
Failure code [DW91KB] Travel Junction Sol Short Circuit 1030
Failure code [DWA2KA] Attachment Sol Open Circuit 1032
Failure code [DWA2KB] Attachment Sol Short Circuit 1034
Failure code [DWK0KA] 2-Stage Relief Sol Open Circuit 1036
Failure code [DWK0KB] 2-Stage Relief Sol Short Circuit 1038
Failure code [DWK2KA] Variable Back Press Sol Open Circuit 1040
Failure code [DWK2KB] Variable Back Press Sol Short Circuit 1042
Failure code [DWK8KA] Swing Press C/O Sol Open Circuit 1044
Failure code [DWK8KB] Swing Press C/O Sol Short Circuit 1046
Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit 1048
Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit 1050
Failure code [DXA9KA] PC-EPC (R) Sol Open Circuit 1052
Failure code [DXA9KB] PC-EPC (R) Sol Short Circuit 1054
Failure code [DXE0KA] LS-EPC Sol Open Circuit 1056
Failure code [DXE0KB] LS-EPC Sol Short Circuit 1058
Failure code [DXE4KA] Attachment Flow EPC Open Circuit 1060
Failure code [DXE4KB] Attachment Flow EPC Short Circuit 1062
Failure code [DXE5KA] Merge-divide Main Sol Open Circuit 1064
Failure code [DXE5KB] Merge-divide Main Sol Short Circuit 1066
Failure code [DXE6KA] Merge-divide LS Sol Open Circuit 1068
Failure code [DXE6KB] Merge-divide LS Sol Short Circuit 1070
Failure code [DY20KA] Wiper Working Abnormality 1072
Failure code [DY20MA] Wiper Parking Abnormality 1074
Failure code [DY2CKB] Washer Drive Short Circuit 1076
Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit 1078
Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit 1080
Troubleshooting of electrical system (E-mode) 1082
E-1 Engine does not start (Engine does not crank) 1082
E-2 Manual preheating system does not work 1088
E-3 Automatic preheating system does not work 1091
E-4 Preheating monitor does not light up when preheater is operated 1093
E-5 When starting switch is turned to ON position, machine monitor displays nothing 1095
E-6 When starting switch is turned to ON position (before starting engine), engine oil level monitor lights up in yellow 1098
E-7 When starting switch is turned to ON position (before starting engine), radiator coolant level monitor lights up in yellow 1099
E-8 Coolant temperature monitor lights up in white while engine is running 1100
E-9 Hydraulic oil temperature monitor lights up in white while engine is running 1101
E-10 Charge level monitor lights up while engine is running 1102
E-11 Fuel level monitor lights up in red while engine is running 1103
E-12 Air cleaner clogging monitor lights up in yellow while engine is running 1104
E-13 Water separator monitor lights up while engine is running 1105
E-14 Coolant temperature monitor lights up in red while engine is running 1106
E-15 Hydraulic oil temperature monitor lights up in red while engine is running 1107
E-16 Engine oil pressure monitor lights up in red while engine is running 1108
E-17 Fuel gauge indicates either full or empty and does not move 1109
E-18 Fuel gauge indicates incorrect amount (indicates neither full nor empty) 1110
E-19 Coolant temperature gauge indicates either Min or Max and does not move 1111
E-20 Coolant temperature gauge indicates incorrect temperature (indicates neither Min nor Max) 1112
E-21 Hydraulic oil temperature gauge indicates either Min or Max and does not move 1113
E-22 Hydraulic oil temperature gauge indicates incorrect temperature (indicates neither Min nor Max) 1115
E-23 Content of display on machine monitor is different from that of actual machine 1116
E-24 Machine monitor does not display some items 1117
E-25 Function switch does not work 1118
E-26 Automatic preheating system does not work (In cold season) 1119
E-27 Auto-deceleration monitor does not light up or does not go out when auto-deceleration switch is operated 1120
E-28 Auto-deceleration is not actuated or canceled when lever is operated 1121
E-29 Working mode selection screen is not diplayed when working mode switch is operated 1122
E-30 Engine or hydraulic pump setting does not change when working mode is changed 1123
E-31 Travel speed monitor does not change when travel speed switch is operated 1124
E-32 Travel speed does not change when travel speed is shifted 1125
E-33 Alarm buzzer does not stop sounding 1126
E-34 When starting switch is turned to OFF position, service meter is not displayed 1127
E-35 Service mode cannot be selected 1128
E-36 Any of work equipment, swing and travel does not work 1129
E-37 Any of work equipment, swing and travel cannot be locked 1131
E-38 Machine cannot swing while swing brake cancel switch is canceled 1132
E-39 Swing brake does not operate while swing brake cancel switch is locked 1134
E-40 One-touch power maximizing function does not work or monitor is not displayed 1136
E-41 One-touch power maximizing function cannot be released 1138
E-42 Travel alarm does not sound when machine travels 1139
E-43 Travel alarm does not stop sounding when machine stops 1140
E-44 Horn does not sound 1141
E-45 Horn does not stop sounding 1143
E-46 Wiper monitor does not light up or go out when wiper switch is operated 1144
E-47 Wiper does not operate when wiper switch is operated 1145
E-48 Window washer does not operate when window washer switch is operated 1147
E-49 BOOM LOWER indication is not displayed properly with monitoring function 1148
E-50 ARM DUMP indication is not displayed properly with monitoring function 1149
E-51 ARM IN indication is not displayed properly with monitoring function 1150
E-52 BOOM RAISE indication is not displayed properly with monitoring function 1151
E-53 BUCKET CURL indication is not displayed properly with monitoring function 1152
E-54 BUCKET DUMP indication is not displayed properly with monitoring function 1153
E-55 SWING indication is not displayed properly with monitoring function 1154
E-56 TRAVEL indication is not displayed properly with monitoring function 1155
E-57 Service is not displayed properly with monitoring function 1156
E-58 Attachment hydraulic circuit cannot be changed 1159
E-59 KOMTRAX system does not work properly 1160
Troubleshooting of hydraulic and mechanical system (H-mode) 1161
Information described in troubleshooting table (H-mode) 1161
System chart for hydraulic system 1162
Failure mode and cause table 1164
H-1 All of work equipment, swing and travel operation lacks speed or power 1172
H-2 Engine speed lowers significantly or engine stalls 1175
H-3 Any of work equipment, swing and travel does not work 1177
H-4 Unusual sound is heard from around hydraulic pump 1178
H-5 Fine control performance or response is poor 1179
H-6 Boom operation lacks speed or power 1180
H-7 Arm operation lacks speed or power 1182
H-8 Bucket operation lacks speed or power 1184
H-9 Work equipment does not move in single operation 1185
H-10 Hydraulic drift of boom is large 1186
H-11 Hydraulic drift of arm is large 1187
H-12 Hydraulic drift of bucket is large 1188
H-13 Time lag of work equipment is large 1189
H-14 When part of work equipment is relieved singly, other parts of work equipment move 1191
H-15 One-touch power maximizing function does not work 1192
H-16 In combined operation of work equipment, equipment having heavier load moves slower 1193
H-17 In combined operations of swing and boom RAISE, boom rising speed is low 1194
H-18 In combined operations of swing and travel, travel speed drops largely 1195
H-19 Machine does not travel straight 1196
H-20 Travel speed is too low 1197
H-21 Machine is hard to steer or travel power is low 1199
H-22 Travel speed does not change, or travel speed is too low or high 1201
H-23 One of tracks does not run 1202
H-24 Upper structure does not swing to the right or left 1203
H-25 Upper structure swings only to the right or left 1204
H-26 Swing acceleration is poor or swing speed is low (both right and left) 1205
H-27 Swing acceleration is poor or swing speed is low (either right or left) 1206
H-28 Upper structure overruns excessively when it stops swinging (both right and left) 1207
H-29 Upper structure overruns excessively when it stops swinging (either right or left) 1208
H-30 Shock is large when upper structure stops swinging 1209
H-31 Large unusual noise is heard when upper structure stops swinging 1210
H-32 Swing drift on a slope is large while swing holding brake is applied 1211
H-33 Swing drift on a slope is large while swing holding brake is released 1212
H-34 Attachment circuit cannot be changed while attachment is installed 1213
H-35 Oil flow in attachment circuit cannot be controlled 1214
Troubleshooting of engine (S-mode) 1215
Information mentioned in troubleshooting table (S mode) 1215
S-1 When starting switch is turned to START position, engine does not crank 1216
S-2 When engine cranks, smoke does not come out 1217
S-3 Engine does not start while fuel is injected (Incomplete combustion) 1218
S-4 Startability is poor 1219
S-5 Engine does not pick up smoothly 1221
S-6 Engine stops during operation 1222
S-7 Engine runs rough or is unstable 1224
S-8 Engine lacks power 1225
S-9 Exhaust smoke is black (KDPF clogs up early) 1227
S-10 Engine oil consumption is too much 1229
S-11 Oil becomes contaminated early 1230
S-12 Fuel consumption is excessive 1231
S-13 Oil is in coolant (or coolant spurts or coolant level goes down) 1232
S-14 Engine oil pressure drops 1233
S-15 Fuel is contaminated in engine oil 1234
S-16 Coolant is contaminated in engine oil (Oil becomes cloudy white) 1235
S-17 Coolant temperature rises too high (Overheating) 1236
S-18 Unusual noise is heard 1237
S-19 Vibration is excessive 1238
S-20 Automatic regeneration is operated frequently 1239
S-21 Active regeneration is operated for long 1240
S-22 White smoke comes out in the process of active regeneration 1241
50 Disassembly and assembly 1243
Table of contents 1244
Related information on disassembly and assembly 1246
How to read this manual 1246
Coating materials list 1248
Special tools list 1252
Sketches of special tools 1256
Engine and cooling system 1259
Removal and installation of supply pump assembly 1259
Removal and installation of injector assembly 1264
Removal and installation of cylinder head assembly 1273
Removal and installation of radiator assembly 1293
Removal and installation of hydraulic oil cooler assembly 1295
Removal and installation of aftercooler assembly 1298
Removal and installation of engine and main pump assembly 1300
Removal and installation of engine front oil seal 1312
Removal and installation of engine rear oil seal 1316
Removal and installation of fuel cooler assembly 1319
Removal and installation of fuel tank assembly 1320
Removal and installation of engine hood assembly 1323
Removal and installation of KDPF assembly 1326
Disassembly and assembly of KDPF assembly 1334
Removal and installation of KCCV assembly 1342
Removal and installation of air cleaner assembly 1346
Power train system 1349
Removal and installation of travel motor and final drive assembly 1349
Disassembly and assembly of final drive 1350
Removal and installation of swing motor and swing machinery assembly 1358
Disassembly and assembly of swing machinery 1361
Removal and installation of swing circle assembly 1369
Undercarriage and frame 1370
Separation and connection of track shoe assembly 1370
Removal and installation of sprocket 1372
Removal and installation of idler and idler cushion assembly 1373
Disassembly and assembly of idler 1374
Disassembly and assembly of idler cushion 1377
Disassembly and assembly of track roller 1379
Disassembly and assembly of carrier roller 1381
Removal and installation of revolving frame assembly 1384
Removal and installation of counterweight assembly 1386
Hydraulic system 1389
Removal and installation of center swivel joint assembly 1389
Disassembly and assembly of center swivel joint 1391
Removal and installation of hydraulic tank assembly 1392
Removal and installation of main pump assembly 1396
Removal and installation of control valve assembly 1400
Disassembly and assembly of control valve 1407
Disassembly and assembly of work equipment PPC valve 1414
Disassembly and assembly of travel PPC valve 1416
Work equipment 1419
Removal and installation of work equipment assembly 1419
Disassembly and assembly of work equipment cylinder 1422
Cab and its attachments 1428
Removal and installation of operator’s cab assembly 1428
Removal and installation of operator cab glass (adhered glass) 1433
Removal and installation of front window assembly 1443
Removal and installation of floor frame assembly 1449
Removal and installation of air conditioner unit assembly 1455
Removal and installation of operator’s seat 1459
Removal and installation of seat belt 1461
REMOVE AND INSTALL WORK EQUIPMENT CONTROLLEVER ASSEMBLY1463
Removal and installation of front wiper assembly 1477
Electrical system 1484
Removal and installation of air conditioner compressor assembly 1484
Removal and installation of air conditioner condenser assembly 1487
Removal and installation of engine controller assembly 1489
Removal and installation of pump controller assembly 1491
Removal and installation of machine monitor assembly 1494
Removal and installation of pump swash plate sensor 1496
Removal and installation of mass air flow and temperature sensor 1497
Removal and installation of KOMTRAX terminal assembly 1498
60 Maintenance standard 1501
Table of contents 1502
Engine and cooling system 1503
Engine mount 1503
Cooling system 1504
Power train system 1505
Swing circle 1505
Swing machinery 1506
Final drive 1508
Sprocket 1510
Undercarriage and frame 1512
Track frame and idler cushion 1512
Idler 1514
Track roller 1516
Carrier roller 1518
Track shoe 1519
Hydraulic system 1522
Hydraulic tank 1522
Main pump 1523
Control valve 1524
Swing motor 1534
Travel motor 1536
PPC valve 1539
Solenoid valve 1548
Attachment circuit selector valve (for high-pressure circuit) 1549
Attachment circuit selector valve (for low-pressure circuit) 1550
Center swivel joint 1551
Work equipment 1552
Work equipment 1552
Work equipment cylinder 1560
80 Appendix 1563
Table of contents 1564
Air conditioner components 1565
Precautions for refrigerant 1565
Air conditioner component 1566
Configuration and function of refrigeration cycle 1568
Outline of refrigeration cycle 1569
Air conditioner unit 1571
Dual pressure switch 1578
Air conditioner controller 1579
Compressor 1580
Air conditioner condenser 1581
Sunlight sensor 1583
Outer temperature sensor (outside air temperature sensor) 1584
Procedure for testing and troubleshooting 1585
Circuit diagram and arrangement of connector pins 1587
System diagram 1589
Input and output signals of the air conditioner controller 1590
Parts and connectors layout 1592
Layout of air conditioner related parts and connectors 1593
Testing air leakage (duct) 1596
Testing with self-diagnosis function 1599
How to open the electrical system abnormality record screen in service mode of the machine monitor 1600
Testing vent (mode) changeover 1602
Testing FRESH/RECIRC air changeover 1604
Testing sunlight sensor 1605
Testing (dual) pressure switch for refrigerant 1606
Testing relays 1607
Troubleshooting chart 1 1608
Troubleshooting chart 2 1609
Information in troubleshooting table 1612
Failure code list related to air conditioner 1613
Failure code [879AKA] A/C Inner sensor Open Circuit 1614
Failure code [879AKB] A/C Inner sensor Short Circuit 1615
Failure code [879BKA] A/C Outer sensor Open Circuit 1616
Failure code [879BKB] A/C Outer sensor Short Circuit 1618
Failure code [879CKA] Ventilating sensor Open Circuit 1620
Failure code [879CKB] Ventilating sensor Short Circuit 1621
Failure code [879DKZ] Sunlight sensor Open or Short Circuit 1622
Failure code [879EMC] Ventilating Damper Abnormality 1624
Failure code [879FMC] Air Mix Damper Abnormality 1625
Failure code [879GKX] Refrigerant Abnormality 1626
A-1 Troubleshooting for power supply system (Air conditioner does not operate) 1627
A-2 Troubleshooting of compressor system (Air is not cooled) 1629
A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal) 1632
A-4 Troubleshooting for FRESH/RECIRC air changeover 1634
Troubleshooting with gauge pressure 1636
Testing refrigerant pressure 1639
Precautions for disconnecting and connecting air conditioner piping 1642
Handling of compressor oil 1644
Desiccant replacement 1646
90 Diagrams and drawings 1649
Table of contents 1650
Hydraulic circuit diagram 1651
Symbols in hydraulic circuit diagram 1651
Hydraulic circuit diagram 1655
Electric circuit diagram 1657
Symbols in electric circuit diagram 1657
Electric circuit diagram 1661
Electric circuit diagram for air conditioner unit 1673
INDEX1675

IMAGES PREVIEW OF THE MANUAL:

S.M 27/12/24